In-line shell processing

BACKGROUND

In the print industry, personalization of printed products is known, however, such personalization has been limited in one or more ways. One type of personalization is to print personalized information on generic pages in an offline process, after which the personalized pages can be stacked and delivered to a feeder of a finishing line. The feeder may then deliver the personalized pages to the pocket of the finishing line, where they can then be subsequently assembled. In this system, complicated verification processes are generally required to ensure that specific personalized pages are coordinated into the proper publications.

Another personalization process includes printing personalized information onto individual pages as they are delivered to the pocket on the binding line. This is commonly referred to as a print-on-demand process. Although print-on-demand may eliminate the need for complicated verification controls by repositioning the personalization onto the binding line, the process remains limited to personalization on a page-by-page basis, which is generally unable to match the production speeds of the binding line.

In yet another personalization process, pages of a book are ink-jetted on a finishing line after they are assembled to personalize the books. When personalization of interior pages are desired, traditional processes only permit personalization of less than all of the available print space due to printing and space constraints; they do not permit personalization of any given portion of an entire sheet.

SUMMARY

In one embodiment, a method of printing and assembling a printed product is provided including unrolling a continuous web of paper from a roll on a printing line, printing non-personalized information on the paper on the printing line, printing personalized information on the paper on a finishing line, performing at least one paper conversion step after printing the personalized information to create a personalized signature on the finishing line, and feeding the personalized signature to the finishing line. The personalized signature can be fed into a pocket on the finishing line.

In another embodiment, a method of printing and assembling a printed product is provided including providing a continuous web of paper to a finishing line, a portion of the web being pre-printed with non-personalized information, providing the continuous web of paper to a printer, printing personalized information on the web of paper with the printer associated with the finishing line, performing at least one paper conversion step to the web of paper on the finishing line after printing the personalized information to create a personalized signature, and feeding the personalized signature to the finishing line. The personalized signature can be fed to a pocket associated with the finishing line.

In yet another embodiment, a method of printing and assembling a printed product is provided including providing a plurality of sheets on a binding line, each of the plurality of sheets having non-personalized information printed thereon, feeding the plurality of sheets to a printer on the binding line, printing personalized information on the plurality of sheets on the binding line, performing at least one paper conversion step to the plurality of sheets after printing the personalized information to create a plurality of personalized signatures on the binding line, and feeding each of the plurality of personalized signatures to the binding line. Each of the plurality of personalized signatures can be fed into a pocket on the binding line.

In yet another embodiment, a method of printing and assembling printed product is provided including providing a pre-printed substrate to a finishing line, personalizing at least apportion of the pre-printed substrate, performing at least one paper conversion step to the pre-printed substrate on the finishing line to create a signature, and providing the signature to the finishing line. The signature can be provided to a pocket associated with the finishing line.

Each of the above-described methods can be done in an in-line process.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1</figref> is a schematic of a printing line according to some embodiments of the present invention.

<figref idref="DRAWINGS">FIG. 2</figref> is a schematic of a finishing line according to some embodiments of the present invention.

<figref idref="DRAWINGS">FIG. 3</figref> is a schematic of a printing line according to some embodiments of the present invention.

<figref idref="DRAWINGS">FIG. 4</figref> is a schematic of a finishing line according to some embodiments of the present invention.

<figref idref="DRAWINGS">FIG. 5</figref> is a top view of a sheet according to some embodiments of the present invention.

<figref idref="DRAWINGS">FIG. 6</figref> is a top view of the sheet cut into individual pages according to some embodiments of the present invention.

<figref idref="DRAWINGS">FIG. 7</figref> is a perspective view of a stack of sheets that forms a signature according to some embodiments of the present invention.

DETAILED DESCRIPTION

Before any embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

Referring to <figref idref="DRAWINGS">FIG. 1</figref>, a printing press <b>10</b> for printing a number of repetitive images upon a substrate (e.g., paper), in the form of a web <b>12</b> for example, is illustrated. The printing press <b>10</b> is utilized to print generally static (generic) information on the web <b>12</b>. The printing press <b>10</b> illustrates a web offset press that includes a reel stand <b>14</b> that supports a reel <b>16</b> of the web <b>12</b>. It should be noted that the invention is equally applicable to sheet fed presses and other non-offset presses such as gravure presses and newspaper presses for example.

The printing press <b>10</b> includes printing units <b>18</b>, <b>20</b>, <b>22</b>, and <b>24</b>, each of which prints in a different color ink. In the illustrated printing press <b>10</b>, the first printing unit <b>18</b> encountered by the web <b>12</b> prints with black ink and the other printing units <b>20</b>, <b>22</b> and <b>24</b> print with other colors. For example, the printing unit <b>20</b> may print in magenta ink, the printing unit <b>22</b> may print in cyan ink, and the printing unit <b>24</b> may print in yellow ink. It should be understood, however, that the invention is capable of being carried out with printing units that print in different colors, and/or with fewer or additional printing units. It should also be understood that while the web <b>12</b> itself is generally monochromatic, the color of the web <b>12</b> can be any color, including, but not limited to, white, brown, off-white, yellow, etc. Moreover, sheets may be used in place of a web.

The printing press <b>10</b> includes a drive system <b>26</b>, including drive rollers <b>28</b>, that moves the web <b>12</b> from the reel <b>16</b> through each of the printing units <b>18</b>, <b>20</b>, <b>22</b>, and <b>24</b>. The images printed by each of the printing units <b>18</b>, <b>20</b>, <b>22</b> and <b>24</b> overlap to create composite multi-color images on the traveling web <b>12</b>.

Each printing unit <b>18</b>, <b>20</b>, <b>22</b>, and <b>24</b> includes a pair of parallel rotatable blanket cylinders <b>30</b> and <b>32</b> that nip the web <b>12</b>. Each printing unit <b>18</b>, <b>20</b>, <b>22</b>, and <b>24</b> further includes a plate cylinder <b>34</b> which has a printing plate thereon, and which applies an ink image to the blanket cylinder <b>30</b>. Optionally, if it is desired to print both sides of the web <b>12</b>, each printing unit <b>18</b>, <b>20</b>, <b>22</b>, and <b>24</b> will further include a plate cylinder <b>36</b> which has a printing plate thereon, and which applies an ink image to the blanket cylinder <b>32</b>. The blanket cylinders <b>30</b> and <b>32</b> transfer the ink images, received from the plate cylinders <b>34</b> and <b>36</b>, to the web <b>12</b>. The printing units <b>18</b>, <b>20</b>, <b>22</b>, <b>24</b> can print any place on the web <b>12</b> where an image is desired, but also can leave unprinted spaces on either or both sides of the web <b>12</b> to permit personalized information to be added to the web <b>12</b> at a later time.

After exiting the printing stations <b>18</b>, <b>20</b>, <b>22</b>, and <b>24</b>, the web <b>12</b> is guided through various processing units as desired, such as a dryer <b>38</b>, a chill stand <b>40</b>, and a coating machine <b>42</b>. The web <b>12</b> can then be cut into ribbons <b>44</b> by cutter <b>45</b>, if desired, and re-rolled to form a plurality of reels <b>46</b>. In the illustrated embodiment, the web <b>12</b> is cut into three ribbons <b>44</b>, but the web <b>12</b> could be cut into more or fewer ribbons <b>44</b>, depending upon the given parameters and variables of each individual printing operation. In another embodiment, the web <b>12</b> is re-rolled to form a single reel <b>46</b> without cutting the web <b>12</b> into ribbons <b>44</b>. As described below, the term pre-printed shell <b>48</b> is used to describe either the re-rolled web <b>12</b> or the re-rolled ribbons <b>44</b>, both of which have generally static (or generic) information printed thereon.

A personalization line <b>49</b> is shown in <figref idref="DRAWINGS">FIG. 2</figref>. One of the plurality of reels <b>46</b> is supported on a reel stand <b>50</b> and the pre-printed shell <b>48</b> is unrolled from the reel <b>46</b> and can be directed through a buffer <b>52</b>. The buffer <b>52</b> may include a plurality of stabilizers <b>54</b> to adjust the tension of the pre-printed shell <b>48</b>, as well as the timing of unrolling the reel <b>46</b>. In the illustrated embodiment, a plurality of stabilizers <b>54</b> is also positioned outside the buffer <b>52</b>. The buffer <b>52</b>, although only shown in <figref idref="DRAWINGS">FIG. 2</figref>, can be positioned anywhere along the printing or binding lines shown in <figref idref="DRAWINGS">FIGS. 1 and 2</figref>, or multiple buffers <b>52</b> can be provided along the printing or binding lines of <figref idref="DRAWINGS">FIGS. 1 and 2</figref>.

The reels <b>46</b> can be stored between being re-rolled in <figref idref="DRAWINGS">FIG. 1</figref> and being unrolled in <figref idref="DRAWINGS">FIG. 2</figref>. In another embodiment, the reels <b>46</b> are transferred directly after being re-rolled in <figref idref="DRAWINGS">FIG. 1</figref> to being un-rolled in <figref idref="DRAWINGS">FIG. 2</figref>, without a time delay in between. In still another embodiment, the pre-printed shell <b>48</b> can be transferred directly from the coating machine <b>42</b> to the buffer <b>52</b>, without being re-rolled and un-rolled.

The pre-printed shell <b>48</b> is then directed through at least one printer <b>56</b> that can print on the unprinted portions of the pre-printed shell <b>48</b> to add personalized information and to thereby form a printed web <b>58</b> that includes both generic and personalized information. The personalized information can be printed anywhere on the pre-printed shell <b>48</b>. In the illustrated embodiment, three printers <b>56</b> are included above the pre-printed shell <b>48</b> and three printers <b>56</b> are included below the pre-printed shell <b>48</b>. The quantity of printers <b>56</b> at least partially depends upon the requirements of the individual printing project. It may be desirable to provide one printer <b>56</b> for each page width of the pre-printed shell <b>48</b>.

For example, if the pre-printed web is of a 2×3 arrangement (2 pages by 3 pages), three printers <b>56</b> along the width may be desirable since each printer <b>56</b> will be dedicated to printing on one page width of the pre-printed shell <b>48</b>. Other arrangements and configurations of printers <b>56</b> and various widths of the pre-printed shell <b>48</b> are possible (for example using multiple print units to “stitch” an image together), and these numbers are given by way of example only. The printers <b>56</b> are illustrated on the top and the bottom of the pre-printed shell <b>48</b>. However, it is not necessary to position printers <b>56</b> on both the top and the bottom of the pre-printed shell <b>48</b>. In some embodiments, a flipping plow may be used to flip or rotate the paper to print on the bottom of the pre-printed shell <b>48</b> from above or from a side. A plow can also be utilized to pre-fold the pre-printed shell <b>48</b>. The printers <b>56</b> can be ink-jet, laser or any other types of printers. In one embodiment, the printers <b>56</b> positioned below the pre-printed shell <b>48</b> are laser printers.

In other embodiments, a press may be placed on the front end of the personalization line <b>49</b>. The press may print static information onto a web or sheets that can then be personalized as described. Alternatively, the press may be a variable printing press that can print both static and personalized information which can then be provided to the personalization line <b>49</b> as described. Non-limiting examples of such variable presses may include digital ink-jet or toner based presses.

The printed web <b>58</b> includes a plurality of sheets <b>69</b> (see <figref idref="DRAWINGS">FIG. 5</figref>) that repeat along the continuous length of the printed web <b>58</b>. The printed web <b>58</b> is then fed into a cutter/folder <b>60</b> that performs at least one conversion step to the printed web <b>58</b>. The cutter/folder <b>60</b> can convert the printed web <b>58</b> by cutting the printed web <b>58</b> into ribbons, cutting the printed web <b>58</b> to length, or both. The cutter/folder <b>60</b> can convert the printed web <b>58</b> by folding the printed web <b>58</b> (such as bi-folding, tri-folding or z-folding), before or after cutting, or instead of cutting the printed web <b>58</b>. The cutter/folder can also partially cut the printed web <b>58</b>, such as cutting perforations to enable a user to tear out a section, or cut out a window in a portion of the printed web <b>58</b>. A converted web <b>62</b> is formed by performing at least one paper conversion step. Performing at least one paper conversion step after the web has been fully printed and just prior to assembling a book from the printed web <b>58</b> provides the advantage of maintaining the web <b>58</b> as one piece, even after the web <b>58</b> is fully printed on, so that the various pages can be kept together without complicated tracking, as was required in the prior art. Further, printing anywhere on the surface area of the web is possible. In one embodiment, the pre-printed shell <b>48</b> is fed into the cutter/folder prior to being fed through the printers <b>56</b>.

After at least one conversion step, the converted web can be stacked into a stack <b>62</b> that includes a plurality of pages <b>65</b> that collectively form one signature <b>64</b>. <figref idref="DRAWINGS">FIGS. 5-7</figref> more clearly illustrate that a sheet <b>69</b> is cut into individual pages <b>65</b> that are folded and stacked to form a signature <b>64</b>. The signature <b>64</b> is fed directly to an individual pocket feeder <b>66</b> on a binding line <b>71</b>. The binding line <b>71</b> forms a part of the finishing line <b>67</b> illustrated in <figref idref="DRAWINGS">FIG. 2</figref>. A plurality of the pockets <b>66</b> may operate to selectively feed associated signatures <b>64</b> (i.e., a portion of a book) to a conveyor line <b>68</b> to assemble different versions of a single publication. The conveyor line <b>68</b> can be a gathering chain onto which a plurality of signatures <b>64</b> is stacked to assemble a book. A stream of books including different personalized book versions may be produced in a prearranged order, for example, in zip code order, according to a first mailing list for that stream of books.

In some embodiments, personalized signatures can be fed into one or more of the pocket feeders <b>66</b>. For example, the illustrated personalization line <b>49</b> may provide personalized signatures to one or more of the pocket feeders <b>66</b> on the binding line <b>71</b>. Alternately, a dedicated personalization line can be provided for each respective pocket feeder <b>66</b> that is to receive personalized signatures. Additional personalization lines may have at least one printer <b>56</b> and/or one cutter/folder <b>60</b>. In embodiments in which less than all of the pockets <b>66</b> receive personalized signatures, other pockets <b>66</b> can receive non-personalized signatures. The pockets <b>66</b> that receive non-personalized signatures can each have a cutter/folder <b>60</b> associated therewith, or can simply be provided a stack of non-personalized signatures that are printed and cut on the printing line <b>10</b>.

The signature <b>64</b> can be fed directly into the pocket <b>66</b> at production speed. Production speed for a binder is between about 6,000 and about 20,000 books per hour whereas production speed for a stitcher is between about 10,000 to about 30,000 books per hour. The signature <b>64</b> (including those with personalized information) may be fed into any of the pocket feeders <b>66</b> at production speed. The present invention allows personalized books to be created at production speed in the binding line <b>71</b>.

As shown in <figref idref="DRAWINGS">FIG. 2</figref>, the stream of books is fed from the binding line <b>71</b> to a saddle print stand <b>70</b>. The saddle print stand can <b>70</b> include at least one printer <b>72</b>, such as an ink jet printer, that prints enhancements to the title of the publication and/or other information on one or more printed products.

As the books are conveyed, a plow device <b>84</b> may be operable to open each book so that a printer <b>86</b>, such as an ink jet printer, can print on an inside page of the book. For example, personalization such as the name, address and customer number or other relevant information corresponding to the intended recipient can be printed on the order form of a book. Optionally, a cardfeeder <b>74</b> selectively inserts various cards into each book. Each book is stitched and then trimmed at respective stations <b>76</b> and <b>78</b>. Although a saddle stitcher finishing line <b>67</b> is illustrated, a perfect bind finishing line can be utilized in another embodiment.

After trimming, an inspection system <b>80</b> may be used to inspect each book (for example, by measuring its squareness) to detect unacceptable books. An unacceptable book can be rejected and a generic book is fed at location <b>82</b> to fill the slot of any previously rejected book, so as to maintain the zip code order of the demographically produced books.

In alternative embodiments, when an unacceptable book has been rejected, the system can identify that book and control the re-manufacture of the signatures used to make the rejected book by the methods described herein (e.g., print, optionally personalize, convert and deliver to the line). In this embodiment, the control system can identify which bundle of books should have contained the rejected book and control the diversion of that bundle of books from the bundles containing the correct number and order of books using a bundle diverter. The control system may also control and monitor which book has been rejected and where the regenerated book is in the manufacturing process and line. Once the regenerated signatures are used to re-build the rejected book, the control system can control the diversion of the regenerated book so that it can then be combined with the diverted bundle in desired order, for example in pre-sort order for mailing. The bundle can then be recombined with the other bundles in desired order.

Each book is next directed to a mailtable <b>84</b>. Here, additional personalization and/or customization may occur. For example, each book then can be directed to an additional ink jet printer <b>88</b> which can provide additional personalization on an outside page of the book. For example, the name and/or address of the intended recipient can be printed on the outside of the book. As mentioned, the books may be produced in a desired order, such as zip code order.

<figref idref="DRAWINGS">FIGS. 3 and 4</figref> illustrate another embodiment of a printing press <b>110</b> and a finishing line <b>167</b> according to the present invention. This embodiment employs much of the same structure and has many of the same properties as the embodiments of the printing press <b>10</b> and finishing line <b>67</b> described above in connection with <figref idref="DRAWINGS">FIGS. 1 and 2</figref>. Accordingly, the following description focuses primarily upon structure and features that are different than the embodiments described above in connection with <figref idref="DRAWINGS">FIGS. 1 and 2</figref>. Reference should be made to the description above in connection with <figref idref="DRAWINGS">FIGS. 1 and 2</figref> for additional information regarding the structure and features, and possible alternatives to the structure and features of the printing press <b>110</b> and finishing line <b>167</b> illustrated in <figref idref="DRAWINGS">FIGS. 3 and 4</figref> and described below. Features and elements in the embodiment of <figref idref="DRAWINGS">FIGS. 3 and 4</figref> corresponding to features and elements in the embodiments described above in connection with of <figref idref="DRAWINGS">FIGS. 1 and 2</figref> are numbered in the <b>100</b> series of reference numbers.

After exiting a dryer <b>138</b>, a chill stand <b>140</b>, and a coating machine <b>142</b>, the web <b>112</b> is sent through a cutter/stacker <b>143</b> that converts the web <b>112</b> into a pre-printed shell shown as pre-printed stack <b>148</b>. Each sheet <b>169</b> in the pre-printed stack <b>148</b> includes multiple pages <b>165</b>, as shown in <figref idref="DRAWINGS">FIG. 5</figref>.

The pre-printed stack <b>148</b> can be stored temporarily, or moved directly to a binding line, such as the binding line <b>171</b> illustrated in <figref idref="DRAWINGS">FIG. 4</figref>, which includes a personalization line <b>149</b>. The pre-printed stack <b>148</b> is then directed through one or more printers <b>156</b> that can print on the unprinted portions of the pre-printed stack <b>148</b> to add personalized information and to thereby form a printed stack <b>158</b>. The personalized information can be printed anywhere on the pre-printed stack <b>148</b>. In the illustrated embodiment, three printers <b>156</b> are included above the pre-printed stack <b>148</b>. The quantity of printers <b>156</b> at least partially depends upon the requirements of the individual printing project. It may be desirable to provide one printer <b>156</b> for each page width of the pre-printed stack <b>148</b>. For example, if the pre-printed web is of a 2×3 arrangement (2 pages by 3 pages), three printers <b>156</b> along the width may be most desirable, since each printer <b>156</b> will be dedicated to printing on one page width of the pre-printed stack <b>148</b>. Other arrangements and configurations of printers <b>156</b> and various widths of the pre-printed stack <b>148</b> are possible, and these numbers are given by way of example only. The printers <b>156</b> are illustrated on the top of the pre-printed stack <b>148</b>. However, printers <b>156</b> can be positioned the bottom of the pre-printed stack <b>148</b> or on both the top and the bottom of the pre-printed stack <b>148</b>. In some embodiments, a flipping plow may be used to flip or rotate the paper to print on the bottom of the pre-printed stack <b>148</b> from above or from a side. The printers <b>156</b> can be ink-jet, laser or any other known printer.

The printed stack <b>158</b> is then fed into a cutter/folder <b>160</b> that performs at least one conversion step to the printed stack <b>158</b>. The cutter/folder <b>160</b> can convert the printed stack <b>158</b> by cutting the printed stack <b>158</b> to width, cutting the printed stack <b>158</b> to length, or both. The cutter/folder <b>160</b> can convert the printed stack <b>158</b> by folding the printed stack <b>158</b> (such as bi-folding, tri-folding or z-folding), before or after cutting, or instead of cutting the printed stack <b>158</b>. The cutter/folder can also partially cut, such as cutting perforations to enable a user to tear out a section, or cut out a window in a portion of the printed stack <b>158</b>. The converted paper is formed into a stack <b>162</b> by performing at least one paper conversion step. <figref idref="DRAWINGS">FIGS. 5-7</figref> more clearly illustrate an example that shows one sheet <b>69</b> that includes multiple pages <b>65</b> (a 2×2 arrangement that includes four pages <b>65</b> is shown in the illustrated example). The pages <b>65</b> are cut to length and to width and then folded. The pages <b>65</b> are stacked to form a stack <b>62</b> that defines one signature <b>64</b>.

After at least one conversion step, the signature <b>164</b> is fed directly to an individual pocket feeder <b>166</b> in the binding line <b>171</b>. A plurality of the pocket feeders <b>166</b> operate to selectively feed associated signatures (i.e., a portion of a book) from the signature <b>164</b> to a conveyor line <b>168</b> to assemble different demographic versions of a single publication. A stream of books including different personalized book versions is produced in a prearranged order, for example, in zip code order, according to a first mailing list for that publication. As discussed above, some or all of the pocket feeders <b>166</b> can receive personalized signatures <b>164</b> from either personalization lines dedicated to each pocket feeder <b>166</b> or a single personalization line for more than one pocket feeder <b>166</b>.

The signature <b>164</b> can be fed directly into the pocket feeder <b>166</b> at production speed. As discussed above, production speed for a binder is between about 6,000 and about 20,000 books per hour whereas production speed for a stitcher is between about 10,000 to about 30,000 books per hour. The signature <b>164</b> includes personalized data that are fed into any of the pocket feeders <b>166</b> in line at production speed, the present invention allows personalized books to be created at production speed in the binding line <b>171</b>.

The remainder of finishing line <b>167</b> operates in a similar manner to the finishing line <b>67</b> shown in <figref idref="DRAWINGS">FIG. 2</figref>.

Although two specific embodiments have been described, other variations and configurations can be included without departing from the scope of the present invention. Various features and advantages of the invention are set forth in the following claims.